INTERCOOLER UPGRADE INSTALLATION INSTRUCTIONS PART NUMBER D APPLICATION: F87 M2

Transcription

1 INTERCOOLER UPGRADE INSTALLATION INSTRUCTIONS PART NUMBER D APPLICATION: F87 M2 Congratulations for being selective enough to use a Dinan Intercooler Upgrade Kit. We have spent many hours developing this kit to assure that you will receive maximum performance and durability with minimum difficulty in installation. Please take the time to read these instructions and call us if you have any difficulties during the installation. Familiarity with BMW recommended procedures is required to install this kit. These documents are available at DO NOT WORK ON VEHICLES SUPPORTED BY A JACK ONLY. USE SECURE JACK STANDS! PARTS LIST Qty Part # Description 1 D Intercooler Assembly 1 D Diffuser; Undercar 1 D Hardware Kit REMOVE THE STOCK INTERCOOLER: 1. Remove the front bumper per BMW recommended procedure. 2. With the bumper removed, remove the lower cross piece. Remove this lower support and set it aside. This will be reinstalled. 865 Jarvis Drive Morgan Hill, CA Tel: (408) Fax: (408)

2 3. Remove the 4 bolts that hold the bumper beam onto the car. Note -- headlight removal is not required for this step. Remove the 4 bolts from the bumper beam. INS Page 2 of 18 Rev. 12/19/16

3 4. Remove the lower air duct. It is secured with 6 tabs and 2 push pins: 2 push pins 5. Remove the 6 bolts that secure the front brace and remove brace from car. Note that the top two bolts come in from the top. Take care to avoid damaging the fins on the radiator as you slide it past the upper air duct. Remove the 6 bolts that hold the brace. Set it aside. INS Page 3 of 18 Rev. 12/19/16

4 6. Remove the two plastic pieces where the lower air duct was attached to: Push up to release the lower tab. Then you will need to release the upper tabs. Lifting up will release the lower tab and make it easier to unlock the top tabs. 7. Remove the inlet and outlet pipes that are attached to the intercooler: Push the tubes toward the front of the car, then release the clip (see photo below). With the hoses disconnected, remove the 2 bolts from the stock intercooler and remove the unit from the car. To remove the clip, push & hold the clip toward the rear of the car, then use a pick to pry the clip downward. Once released, slide the clip back as shown. Now pull the tube off of the intercooler. During installation, push the hose back on and the clip back into place. Pull on the hose to confirm it is secure. INS Page 4 of 18 Rev. 12/19/16

5 INSTALL THE DINAN INTERCOOLER: 8. On the bumper beam, locate the 2 holes that held the upper radiator duct. Drill out these holes to 17/32 drill bit. 9. Install a rivet nut into each hole using the included installation tool. Refer to the Instructions included with the tool for proper use. Spare rivet nuts are provided for your use if necessary. Rivet nut installed into the bumper beam. INS Page 5 of 18 Rev. 12/19/16

6 10. Modify front brace: Align a straight-edge with the side edges shown and make the two marks. In the center of the brace make a mark about 1/8 below the circle. Cut out lower portion of brace and clean up the edges. AFTER MODIFICATION INS Page 6 of 18 Rev. 12/19/16

7 11. Prepare Dinan intercooler for installation: Insert the 2 rubber mounts and metal sleeves into the top mounts of the Dinan Intercooler. Locate the 2 rubber flaps included in the kit and lay them out in front of the intercooler. Clean the flap using the included alcohol wipes and apply the strips of double sided tape at the indicated locations. Apply the double-side tape at these four spots. Take the flap that is shown on the right side of the photo above. Slip the brace through the middle slot, with the big hole toward the front of the brace, and the double side tape facing down. Repeat on the other side. Reinstall the brace into vehicle. When you start to install the brace back into the car you will need to fit the second slot. INS Page 7 of 18 Rev. 12/19/16

8 12. With the brace installed... Take the open slot, and have it straddle the brace and the bracket where the brace bolts onto. Install the intercooler. Leave the 2 lower mounting screws loose. Place one side in front of the bolt, and one side on the back side. Slip the flap in between the intercooler and radiator as shown in the photo, then tighten the 2 screws. Apply the adhesive to the intercooler and core support. Then place the flap around the upper mount, and install the rivet. Slip the flap under the radiator and apply the adhesive to the intercooler and core support. With the flap around the upper mount, install the rivet to hold the flap in place. INS Page 8 of 18 Rev. 12/19/16

9 13. Reinstall the bumper beam: Use the 4 stock bolts to hold the bumper beam in place, but leave them loose and do not tighten yet. Locate the two 8mm bolts from the hardware from the kit. Take the two bolts and washer. Slip them through the upper holes located on the upper air duct as shown in the photo. Tighten the 8mm bolts, then tighten the bumper beam bolts. INS Page 9 of 18 Rev. 12/19/16

10 Cutting the lower air duct: 14. Take the lower air duct that was previously removed from the car, and make marks: Align a straight edge along the front edge, make a mark from the edge of the cutout, measuring 11/16. Then align the straight edge from the top edge to your mark as shown in the photo. Make a mark from the top edge down to the mark you made. From this edge measure 11/16 and make a mark. INS Page 10 of 18 Rev. 12/19/16

11 Flip over the air duct. From the edge measure out ¼ and make a mark. Then measure out a ¼ from the cutout and make another mark. Measure ¼ from the outer edge. Measure ¼ from the edge and make a mark. Repeat for other side. Cut along your marks. Save the cut pieces as they will be used later. Save the cut pieces! INS Page 11 of 18 Rev. 12/19/16

12 Trimming the grill: 15. Place bumper on a body stand: From the outside of the grill, count inward 3 rows, and make a marks on both sides, top and bottom. Measure on the top side of the grill ½ on both sides of the center line of the row, as shown in the photo below. Repeat on other side Center line, measure ½ on both sides, make your cuts. INS Page 12 of 18 Rev. 12/19/16

13 16. On the bottom side of the grill: Mark the center line of the grille. Measure out on both sides of the center line 2-1/2 as shown in the photos below, and mark a connecting line. Repeat marks on the other side, then cut. Measure 2-1/2 out from the center line. Mark from the top edge to the lower edge. Center line. The grill should have 4 spots trimmed out. INS Page 13 of 18 Rev. 12/19/16

14 17. Take the 2 pieces that were cut out during step 14: Using a 1/8" drill bit, match drill 2 holes, one on top and one on bottom. As you are drilling, you will need to drill through both the duct and the grill at the same time (see photos below). Repeat on the other side. Secure the 2 pieces using the rivets included in the kit. Note how the duct is positioned. The long tab is the top. Drill two 1/8 holes through the duct and grill, then install the rivets that are included in the kit. You will be doing this on both sides. Install the rivets from the inside. INS Page 14 of 18 Rev. 12/19/16

15 18. Reinstall the bumper. Make sure the two trim pieces sit on the side of the intercooler tanks, as they can get held up when the bumper is installed. Don't forget to reinstall the lower support. Modify the lower cover: 19. Place lower cover on a workbench and cut off the two tabs as shown. Make sure they are flush with the surface. Remove these 2 tabs. INS Page 15 of 18 Rev. 12/19/16

16 20. Make additional marks as shown in the photos below: Measure down 2 3/8 through the center of the clip, and make a mark as shown. Measure 5 3/8 through the center of the same clip, and make another mark. On your top mark, measure from the inside of the rib ¼, and make a mark. On the bottom mark, measure from the inside of the rib ¾, and make a mark. Connect your marks using a long straight edge. With your trapezoid marked out, double check your measurement. Cut out the marked section. Measure ¼ in from this rib (ame on both sides). Make a mark. Measure ¾ in from the rib (same on both sides). Make a mark. Measure 2 3/8 from the edge. Make a mark. Measure 5 3/8 from the edge. Make a mark. Measurement should look close to below. If your marks are correct, cut it out INS Page 16 of 18 Rev. 12/19/16

17 21. Mount the undercar diffuser: Place the Dinan diffuser into the cut out as shown. Make sure it lines up, and mark the mounting holes. Drill the 4 holes using a 3/16 drill bit. Using the hardware supplied in the kit, bolt the air diffuser to the lower slash cover. 22. Install lower cover into car: As you install the cover, make sure the back part of the opening slides into the groove. If you encounter difficulty sliding the cover into the groove, take a small pry bar and lightly pry down, working your way from one end to the other. INS Page 17 of 18 Rev. 12/19/16

18 23. For best performance, please also install the appropriate DINANTronics ECU and software. 24. Using a scan tool or equivalent, clear fault memory after installation is complete. 25. Happy Motoring! INS Page 18 of 18 Rev. 12/19/16